Method of packaging k.d.f. cartons



July 21, 1959 l H. w. WILSON I 2,896,207

l METHOD oF PACKAGING K.D.F. cARToNs original Filed April 9, 1957 s sheets-.sheet 1 TTRIY'Y July 21, 159 H. w. WILSQN 2,896,207

METHOD 0F PACKAGING x.D.F. cARToNs original Filed April 9, 1957 s sheets-sheet 2 IMKMEY Julyv 21, 1959 y H. w. WILSON METHOD oF PACKAGING x-,.D.F. cAR'roNs original Filed April 9, 1957 v I5 Sheets-Sheet 3 mill Il E

Llllmllll mlmlllmmm :NNUU ummm INVENTOR. MY I4( W/Lso rmeNEY United StatesPatent O METHOD F PACKAGING K.D.F. CARTONS Harry W. Wilson, Millbrae, Calif.

Original application April 9, 1957, Serial No. 651,615. Divided and this application October 21, 1957, Serial No. 696,304

Claims. (Cl. S3-3) This invention relates to a method of packaging collapsed cartons. This application is -a division of application Serial No. 651,615, filed April 9, 1957, which was a continuation in part of co-pending application Serial Number 592,185, led lune 18, 1956, now abandoned.

Corrugated paper boxes and cartons are commonly shipped from Vthe manufacturer to the users in collapsed form, which is known in the industry terminology as K.D.F., i.e., knocked down flat. The flat blanksA have been properly slotted, scored, folded, and the two end panels connected by methods that are conventional in the industry, so that all the user has to do is to open the K.D.F. box out and fold over the bottom and top flaps of the integral container.

Heretofore, the shipping of these K.D.F. cartons has presented a packaging problem. The method currently used in the prior art employs small bundles of about twenty-five cartons per bundle, each bundle being secured by wire or twine. This method usually required handling of the bundles by hand, which was costly, or a number of bundles were stacked flat and secured to Wooden pallets, usually of the so-called returnable type but sometimes of the nonreturnable type, for handling by fork-lift trucks. The use of returnable pallets is expensive, due to the necessity of recording their whereabouts and the costs of maintaining them in proper condition and of returning them to the shipper. Also, the shipper must maintain a considerable investment in his pallets to permit circulation and still have enough on hand for each shipment. Nonreturnable palletshave heretofore been still more expensive per use and have not been used to a great extent.

Moreover, standard pallets usually do not conform to the dimensions of the bundled cartons, and consequently when the cartons are stacked on the pallet do not ll the surface of the pallet or else overhang the edges. In either event, space is wasted and it is not possible when using standard pallets to put the maximum number of cartons in the shipping space available in rail cars and trucks.

Thus the use of pallets has involved stacking the corrugated boxes by hand on the pallets. The pallets have been an added expense, their use brought ineciencies in utilization of shipping space, their return to the manufacturer was a nuisance while, if they were not returned, the manufacturer had to buy new ones for each shipment.

One object of this invention is to provide a novel method for packaging K.D.F. corrugated cartons.

Another object of the invention is to provide a method for assembling a self-palletizing bale of K.D.F. cartons.

My invention is characterized by several new features brought together in combination to produce important new results. For one thing, the K.D.F. cartons in my finished bale are stacked on edge. In order to make this feasible they have to be strapped while they are under pressure; the pressure exerted by the strapping is not nearly enough to produce a truly tight package. MyV rinvention calls for exerting pressure at least great enough to squeeze out the air between the cartons and to make fall the sur- 2,896,207 Patented July 21, 1959 ICC faces equiplanar, while the pressure is still less than would damage or crush the cartons. As a result, the pressure forces the K.D.F. cartons together and, once forced together with unevenness and waste air eliminated, they help to maintain themselves together so that there is no undue burden on the straps. The straps retain them as a bundle, but do not apply additional pressure. is very important and is greatly dilerent from the priorart approach, where the stacking was usually done by gravity and where the straps themselves applied whatever pressure was applied. This feature will be explained in greater detail below.

Another important'novel feature of the invention is that there is no pallet in the usual sense; that is, no separate pallet on which the goods are placed. In my invention there is no pallet separate from the package. The bale is self-palletized by straps that hold a pair of runners to the stack. The two runners hold the bale olf the ground, but they are not a pallet; the pallet is the bale with the runners.

Another very important feature of the invention is that it makes possible the provision of self-palletized bales of K.D.F. cartons that are too small to be handled in a single stack by fork-lift trucks, since the forks are normally about 28 to 32 apart. This is accomplished by a novel double stack of the smaller cartons, joined only by locking sheets that are strapped into the bale. By pitting against each other, through the locking sheets, the forces that tend to cause the bale to come apart, the invention holds the bale together. Use is made of the high shear or tensile strength of sheet material when subjected to stretching forces as compared with the weakness of the same material in the face of bending moments. By this novel arrangement, which will be explained in more detail below, it becomes possible to use corrugated paper as the locking sheets, with resultant savings in material costs.

The results of the invention are very surprising in that the frail-appearing bales can be stacked many tiers high. For example, they are often stacked ten tiers high so that the bottom runners carry a load of about 1400 pounds per square foot, or more, without damage to the bottom bales. i Another feature of the invention is that the dimensions of the package are controlled along an axis parallel to the axes of the forks of the lift truck as they enterthe pallet, so that maximum efficiency in loading becomes possible. This feaure likewise is explained in detail below.

An additional feature of the invention is the provision of a divisible package, capable initially of being handled by fork-lift trucks and capable, when divided, of being handled by hand trucks.

Other objects and advantages of the invention will appearV from the following description of a preferred embodiment given in accordance with 35 U.S.C. 112.

In the drawings:

Fig. 1 is an isometric view of a stack of K.D.F. corrugated iibreboard cartons. Two shipping and storing units made by a method embodying the principles ofthe present invention are shown, each unit comprising a selfpalletized bale on the lower layer and two half-size bales as the upper layer. The self-palletized bales shown each include two stacks of cartons like those on the upper layer.

Fig. 2 is a botto-m plan view of one of the self-palletized cartons bales of Fig. l. vation view of the bale as made by the preferred method, just before tipping. y

Fig. 3 is a view in side elevation and partly in section, on an enlarged scale, of a storing and shipping unit embodying the invention, with the lowerlayer being selff It also represents an end ele-` 3 palletized and the upper layer unpalletized, the two layers being normally handled as a unit.

Fig. 4 is a fragmentary view partly in elevation and partly in section of the lower left corner portion of Fig. 3, shown on a further enlarged scale and taken along the line 4-4 in Fig. 2.

Fig. 5 is a fragmentary view in front elevation of a portion of the bottom part ofY the self-palletized bale, near one of the runners that serve as pallet boards or rails.

Fig. 6 is a ow sheet illustrating a preferred method of making a self-palletized bale, according to the presentV invention.

Fig. 7 is a liow sheet illustrating a preferred method of making a three-bale unit according to the present invention.

Fig. 8 is a fragmentary perspective view of a portion ofa bale embodying a modified form of bale made by the method of the invention.

A self-palletized bale 10 madeby a method embodying this invention comprises an appropriately (for maximum utilization of truck or rail car space) sized stack or stacks of collapsed or K.D.F. corrugated paper or breboard boxes 11 secured together on edge by two steel bands or straps 12, 12 of conventional type but used in a novel manner according to a novel method, and resulting in a new kind of package.

While there may be only a single stack of K.D.F. cartons in the bale 10, if these cartons are so largerthat pallet runners can be spaced far enough apart beneath them, an important feature of this invention is its provision of a bale 10 having two stacks 30 and 31 of cartons 11 side by side, with one pallet runner under each stack. To make such a double-stack unit successful, there has to be a way of locking the two stacks together and of preventing the forces of cleavage from tearing apart the locking members. For this purpose, the front and rear ends 13, 14 of the carton bale 10 are covered by two oversize locking sheets 15, 16, preferably of corrugatedpaper, though for some purposes they may be made of breboard or other suitable material. Each cap sheet 15, 16 is folded over against the carton stacks at both its ends to form flanges 17, 18 to form a longitudinal lock of the two stacks 30 and 31 of corrugated paper cartons 11 which comprise the bale 10. The sheets 15, 16 are not mere cover sheets, nor are they present merely to prevent the straps 12 from tearing the edges of the cartons 11. When the flanges 17 and 18 are folded, the sheets 15, 16 become flanged tension sheets, or shear-prevention sheets, or load-carrying locking sheets, that make a unitary bale possible. However, fuller explanation of how they work must be deferred until the remainder of the bale has been described.

Smaller overlength reinforcing or bumper strips 20, 21, preferably of corrugated paper or similar material, are also provided at each end over the cap sheets 1S, 16 and beneath each of the steel bands 12. Portions 22 at each end of the bumper strips 20, 21 are likewise turned over against the carton stacks. The primary purpose of the bumper strips 2i), 21 is to prevent Vthe bands 12 from tearing the locking sheets 15, 16, though they also give some protection to the carton edges. Their function will be better understood after a discussion of the locking sheets 15, 16 which must, for the present, be deferred. In place of the bumper strips 20, 21, four short corner or L-shaped pieces 35 may be used for each band 12', if desired, as shown in Fig. 8, though the structure of Figs. l-S is preferable since it takes fewer pieces, is easier to install, and is much easier to align.

A pair of Wooden boards, pallet rails, or runners 25, 26 is provided along the full length of the bottom of the package 10. The runners 25, 26 are preferably rabbeted lengthwise to provide a long axial or longitudinal groove or rabbet 27- on their outer surface, `and the groove 27 receives the steel band 12 and holds it in the correct 4 alignment. At the same time, the runners 25, 26 help to prevent the band 12 from damaging the carton edges. The alignment of the bands 12 maintains the runners 25, 26 parallel to each other and spaced apart a distance proper to the use of fork-lift trucks. While, in some sizes, it is possible that the runners 25, 26 will be centered relatively to their respective stacks 30 and 31, this is not usually true. Usually, and preferably, the runners 25, 26 are positioned a little outside the centerlines of the stacks 30, 31 so that actually the forks of the lift truck will be positioned at these centerlines when they lift and move the bale 10. So the bands 12 are all that secure the pallet rails 25, 26 to the package 10. Without the package 10, the boards 25, 26 are loose, and there is no pallet. Without the runners 25, 26, there is no pallet. The pallet exists only as a combination of the cartons, bands, and boards; and (in double-stack bales) the locking sheets. The bands 12 are joined in the normal manner by band locks 32, such as are made by commercial strapping machines.

It will now be seen from Fig. 2 that where there are two stacks 30, 31 of cartons 11 in the one table 10, only the flanged locking sheets 1S, 16 at the ends link the two stacks 30, 31 together. The oversize sheets 15, 16 are able to link the two stacks 30, 31 together and hold the bale 10, not only because of their having strength in themselves, but also because they are in combination with the cartons 11 and bands 12, and because the alignment of the two runners 25, 26, usually just outside the centerlines of their respective stacks 30, 31 centers each stack on a fork of the forklift truck, so that the stacks 30, 31 do not tend to slip away from each other.

More important, however, is the effect of the flanges 17, 18 in conjunction with the sheets 15, 16. These flanges 17 and 18 serve to pit against each other the disruptive forces that tend to split the bale 10 in two. Looking for the moment at Fig. l, it can be seen that the bottom anges 17 are subject, when the bale 10 is stored, Vto rotational forces of each stack 30, 31 inward about the runners 25, 26 as pivots, especially since the runners 25, 26 are preferably located out beyond the centers of their respective stacks 30, 31. In etfect this is a force acting from the upper corners down to the center of the lower ange` 17. This force, however, is apposed by a force tending to stretch the flange 18. The horizontal components of force at the lower flange 17 are therefore inward' toward the center, while the horizontal components at the upper ange 18 are outward from the center.

Now, note that the corrugations of the sheets 15, 16 run horizontally, widthwise of the stack. It is well known that even an ordinary sheet of paper, though easily torn apart by forces acting perpendicular to the sheet, has great tensile strength against forces trying to stretch the paper in its own plane. That is, in general, what is happening at the upper flange 18 when the bale 10 is stored. So the corrugated sheets 15, 16, with the corrugations extending widthwise, are well able to resist this stretching force and therefore to give strength to the bottom anges 17. Itis very important, however, that each flange 17, 18 is supported also by the-normally vertical portion of the sheets 15, 16, for this means that each of them acts like an L-beam instead of like a at strip and so do not bend readily. So they are given great rigidity by the resistance of the verticalportions to'shearing forces acting along their planes. This would be true whether the cap sheet 15, 16 were unitary, as shown, or whether it were separated into two- L-shaped strips, at each edge, but the unitary structureV is both somewhat stronger and easier to apply. Y A

The foregoing paragraph/indicates that the flanges 17, 18 shouldY have substantial width, preferably at least 2". Most flanges 17, 18 are preferably about 4 to 6" wide and may, of course, be as wide as desired. For some uses, and, some material, they may be narrower than 2, but that is not vgenerally advisable. In any event, in order tov hold them as flanges, the anges 17 should be wide enough so that when they are folded under, they are sandwiched between their runners and 26 and the associated stacks and 31 and are locked in place.

As the foregoing demonstrates, the locking `sheets 15, 16 may be made from corrugated paper because they have to resist only forces along their plane. This points out the importance of the bumper strips 20, 21 (or 35) in preventing any tearing of the locking sheets 15, 16, for once torn they would not be strong and able to resist lshear. Also, the preferable widthwise direction of corrugation helps to prevent the bands 12 from tearing them.

As shown in the drawings, the assembled bale 10 serves as its own pallet, the two runners 25, 26 holding the package off the ground and giving space at 33 for the entry of the forks. Thus, the combination of locking sheets, cartons, runners and bands results in a iirmly secured package that can be handled directly by lift trucks. By simplycutting the bauds 12, the package is ready for use, and the runners, straps, locking sheets, and bumper strips are not expensive; so they may be thrown away, or allparts except the straps may, if desired, be re-used. It is obvious that the two rabbeted boards 25, 26 are much less expensive than a complete pallet; and, in fact, the total cost of the locking sheets, bumper strips, straps and runners is only a fraction of the cost of a pallet. Moreover, the bale 10 is much more convenient than a conventional pallet holding a load of tied packages of cartons. There is much less excess weight for shipping.

There is also much less waste space in shipping or storing since there is no empty space on the pallets nor is there any overhang, and since the space 33 provided by the runners 25, 26 is no more than is needed and convenient for entry of the forks of the lift truck.

Moreover, the dimensions of the package are under quite a bit of control, especially the dimension that counts most. Thus, although the height of each package is determined by the width or length of the K.D.F. carton, height is not usually a serious limiting factor, since the cartons are frequently carried on flat-bed trucks or rail cars. The width of each package is also determined by the carton size, but it is not critical either. The length, the important thing, is selected by how many cartons are in the stack, since the thickness of each carton is relatively small; so the length can be varied as desired. For example, each package may be exactly 48 long or exactly two pacakegs wide, when the standard legal width of the trucks is 96". Or any other desired dimension can as easily be achieved. Moreover, this dimensional control is along the correct dimension, parallel to the forks of the lift truck instead of transverse to them, and so is Very convenient for loading flat-bed trucks. In that way, the maximum load can be loaded in every instance; for example, by two rows of packages, each row extending 48" across the 96" truck width, or exactly half way, no matter what the size of the K.D.F. carton is.

This dimension control again brings up the fact that the K.D.F. cartons are stacked on edge, for Without this stacking on edge, dimensional control is not possible, and height is the least important dimension to control.

On-edge bales are feasible only because the stacks are pre-pressurized, that is, are held under high pressure before and during the strapping operation. Otherwise, the cartons tend to expand or incline to one side and give poor support. It is once again like the old parable of the package of fagots bound together versus a series of individual sticks. The individual cartons are not very stable on edge, but many cartons pressed together are very stable indeed, and huge stacks of many tiers are quite practical.

The pressure must be much greater than the pressure normally exerted by any strapping gun I know of. The minimum pressure unsable is at least an amount necessary to squeeze out the air between the cartons so that they will hold themselves together, enough to flatten them and press out all unevenness, make all surfaces equiplanar and each carton in firm contact with the adjacent carton. For corrugated paper K.D.F. cartons, this minimum pressure will be about 4 p.s.i.a., though it may be lower or higher for packaging other materials.

The maximum pressure usable is simply that which the material will sustain without damage, such as being crushed so that the corrugations are destroyed. Normally, for corrugated paper, that will be about l5 p.s.i.a., though it may be different for different materials, and there will be differences in corrugated paper due to the different type of iiutes in use, etc. For K.D.F. cartons 11 that are ten square feet in area, that is a range of about 5600 pounds to about 21,000 pounds per carton. Excellent results for many cartons are obtained at pressures of 8-12 p.s.i.a.

This pre-pressurization helps the bands 12, for they have less to hold, once the cartons are so pressurized. Also, it makes possible the very high on-edge stacking. For lower stacks, less pressure can be used, but the bale 10 will not be as tight.

It will also be seen in the drawings that the bale 10 of this invention can be used in conjunction with a pair of bales 40, 41 having no boards and comprising prepressurized (as above) single stacks of cartons 11, each held together preferably by only a single band 42, identical in type to the bands 12, and locked at 43. Bumper strips 44, 45 substantially identical to the bumper strips 20, 21 may be used to protect the corners 46 and ends or vfaces of the packages 40, 41, just as the corners 34 and faces of the bale 10 are protected. This means a saving in locking sheets and runners because the bales 40, 41 may be packed on top of each bale 10 of this invention to provide a basic unit 50- which is thenceforward always handled as a unit by the fork lift truck. In every unit 50, one or more layers of unpalletized bales 40, 41 are supported and carried by a lower` layer, comprising a self-palletized bale 10. Units 50 may be stacked on each other as shown in Fig.l. As implied, there may be one, two, or more upper layers for each lower layer, determined partly by the size of the K.F.D. carton concerned.

Where desired, as with large cartons, there may be only lone stack in the bale 10, and one 4bale 40 will then combine with one bale 10 to comprise the unit 50. Also, more stacks per bale 10 or more bales 40, 41, etc., may again be used, if feasible.

A small portion of a` modified form of bale is shown in Fig. 8. Here, the only change is that instead of using the bumper strips 20, 21 (two for cach strap 12), L-shaped strips 35 are used (four for each strap 12). These L-shaped strips 35 are entirely suitable and have the advantage of lowering the material cost somewhat; but they usually take more time to install, so the strips 20, 21 are generally to be preferred.

The preferred method of this invention, which has been explained somewhat already, comprises the following steps shown in Figs. 6 and 7 .y

A plurality of K.D.F. cartons l1 are formed into' one or more (preferably two) stacks 30, 31. The cartons 11 in the `stacks 30, 31 may be on edge, as in the finished bale 10, or they may more conveniently lbe horizontal, as in Fig. 2 and in Fig. 6.

The oversize locking sheets 15, 16 are placed at each end 13, 14 to hold the one yor more stacks 30, 31 together. Their ends 17, 18 are folded over against the stack. In the` preferred method (see Figs. 2 and 6) one locking sheet 16 will be beneath the stacks 30,31 and one sheet 15 will be on top of them. In either event, the side edges of the locking sheets 15, 16 are preferably not oversize, only its lengthwise edges, and these are the ones folded against the stack. If desired, the lower cap sheet 16 may be placed down first and the stacks 30, 31 built upon it, or the stacks 30, 31 can beV made first and lifted up for inseition of the cap sheet 16.

Corner and end reinforcements are next provided, preferably the bumper strips 20,21 at each end, or else by the L-shaped strips 35. ln the preferred method the st-rips are inserted horizontally above the top of the package andV below the bottom. Their overlength ends 22 are folded over. Preferably, the bumper strips 2G, 21 are aligned slightly off-center with respect to their respective stacks 30, 31, as explained previously.

A pair of parallel rabbeted boards or runners 25, 26 are positioned, rabbeted face out, along the end of the package which will eventually serve as the lower edge. The runners 25, 26 overlie the folded ends 17 and 18 of the cap sheets 15, 16 and the folded ends 22 of the bumper strips 20, 21. They are spaced so as to be symmetric with the package, preferably out just'beyond the center of their respective stacks 30, 31 and a distance apart from each other suitable for the entry therebetween of a fork-lift truck. Preferably the package is at this time on one side, as shown in Figs. 2 and 6, with one cap sheet 16 on the bottom and with the boards 25, 26 extending. vertically along a vertical end of the package. Later, the package will `be turned over, and the boards 25, 26 will then be on the bottom.

While the boards 25, 26 are held in place and while the stacks 30, 31 are held under pressure (as described before, and preferably at a pressure between 4 p.s.i. and 15 p.s.i. for corrugated paper cartons), preferably in a press, the pair of metal bands 12 is passed around the bale 10. The bands 12 are channeledV in the groove 27 in the runners 25, 26. The bands 12 also overlie the bumper strips 20, 21 which protect the corner edges 34 and keep the bands 12 from Ibiting into the locking sheets 15, 16 and tearing them, or from damaging the cartons 11. They are preferably oif-center with respect to the stacks 30, 31, as explained before. Then the ends of the bands 12 are secured together at 32 to make a tight bale 10.

For some uses, the bale may now be turned over 90, so that it rests on the lboards 25, 26, thereby becoming a self-palletized load. This step is, of course, omitted when the cartons 11 are stacked on edge. It is also deferred when making the unit 50.

For making a double unit 50, two other bales 40, 41 are made as shown in Fig. 7, by stacking K.D.P. cartons, applying a bumper strip 44 or 45 at or reasonably near the centerline of each end of each stack, applying pressure as stated heretofore, and then applying a strap 42 around each stack, the corners 46 being protected by the bumper strips 44, 45, or by L-shaped strips like the strip 35.

The bales 40, 41 are then placed beside the bale 10, preferably before the bale is turned, in the preferred method. However, the bale 10 may be turned over before the bales 40, 41 are on top of it, if desired. In any event, the final step in the preferred method is to turn over the three bales 10, 40 and 41, to put the unit 50 on the pallet boards 25, 26.V

One further problem solved by the present invention should be mentioned. Many small manufacturers do not have fork-lift trucks and handle the cartons on hand trucks. But a load that can easily be handled by a forklift truck is much too heavy for normal hand-truck use, and so the problem is to provide a package that can be adapted easily for use by both fork-lift and hand trucks. In the case of the packing unit shown at the bottom of Fig. l, this may be done by taking a knife or other cutting tool and splitting the cap sheet 15 along a line coplanar with the plane where the stacks 30 and 31 meet,

y or in other words an extension of the line 47, where'the two stacks of the upper layer meet.

However, a still more convenient and adaptable package is shown in the upper part of Fig. 1, where cap sheets 15a and 16a are each provided'wit-h a tear strip 48, as a 8. severing means. Bysimply pulling the tear'strip 48, the two stacks 30 and 31 are readily divided from each other. The tear strip 48 may be a strip of strong tape on the inner face of each sheet 15a or 16a, with starting tabs provided by cuts 49 through the sheets. The two tabs are then grasped and pulled in opposite directions along the tear strips 48 to sever the bale. In fact, it is not essential that the strip 48 be torn along its full length, since all that is necessary is to tear it to the point where the weight of the package itself will tear the remainder, and this is readily accomplished. Thus the unit 50 at the upper half of Fig. 1 is adaptable for either fork-lift trucks or hand trucks. It may be handled by the carton manufacturer by fork-lift trucks in his warehouses and when loading it on trucks or rail cars, and it may be even unloaded later on 'by fork-lift trucks if desirable, |but from that point on it can be handledby hand trucks, once the tear strip 48 has been pulled to divide the cap sheets 15a and 16a into two pieces.

To those skilled in the art to which this invention relates,rmany changes in Vconstruction and widely differing embodiments and applications of the invention will suggest themselves without departing from the sipirt and scope of the invention. The disclosures and the description herein are purely illustrative and are not intended to be in any sense limiting. For example, any of the many well-known types of -tear strips may be used in place of the one shown. Also, the rabbets in the boards, while preferable any very convenient, are not essential. Furthermore, the units may be three or four or more layers high instead of two layers high.

I claim:

1. A method for making a self-palletized package of K.D.F. corrugated cartons, comprising the steps of: stacking K.D.F. cartons horizontally in two stacks, side by side, inserting a bottom oversize locking sheet beneath the resultant stacks and an upper oversize locking sheet over said stacks; exerting pressure on said stacks sufficient to make the cartons equiplanar and squeeze out the air ybetween them without damage to the individual cartons; folding the portions of said locking sheets that extend beyond said stacks against those faces which are common tov both of said stacks; placing overlength bumper strips to extend from end to end at spaced intervals over the top of the upper locking sheet and beneath the bottom of the bottom locking sheet; folding the overlength end portions of said bumper strips against said faces of said stacks and the folded portions of said locking sheets; positioning rabbeted runners, rabbet outward, against one of said faces of the stacks with the lower surface of their end portions resting on the folded end portions of said bumper strips; passing metal bands around said stacks while they are still under pressure, each said band lying in the rabbet of a said runner and overlying a said bumper strip at the top, bottom, and folded end portions; securing the ends of said bands together tightly to form a baled stack; and then turning said resultant baled stack to rest it on said runners, which are then used as pallet rails.

2. A method for packaging K.D.F. corrugated cartons, comprising the steps of: stacking the K.D.F. cartons on edge; placing oversize vertical end sheets at each end of the stack parallel to the cartons; folding portions thereof back over aI portion of what is to become the top and bottom the stack; providing L-shaped strips at spaced intervals over the top and' bottom edges of said end sheets Vat each side, two strips along each edge to total eight strips; positioning two rabbeted boards on what is to become the bottom extending across parallel to each other and in hold down relation with the L-shaped strips at opposite ends; and securing a pair of metal bands therearound, said bands lying in the rabbets of said boards and overlying said L-shaped strips at the top to comprise a palleted package lwherein the end 9 sheets and their folded-back por-tions prevent twisting and tearing 4in between said bands.

3. A method for making a self-palletized package of K.D.F. corrugated cartons, comprising the steps of: stacking two stacks of K.D.F. cartons; applying flanged locking means parallel to the cartons at opposite extremities of the resultant stacks with the flanges against the edges of the end cartons along two opposite faces common to both stacks; placing said stacks under pressure; positioning grooved runners, groove outward, against one of said opposite faces of each stack bridging between two said flanges, the ends of said runners being in hold down relation to said flanges; passing metal bands around each said stack, each said band lying in a groove;

stack and holding said stacks and tension means under a pressure of between about 4 and l5 p.s.i. while applying a pair of runners along the portion that is to become the bottom, with the ends of said runners in hold down relation with said flanges, and then securing fastening means around said stacks and said runners, the minimum 4 p.s.i. pressure being enough to squeeze out the air between the KDF. cartons, to flatten them, to press out unevenness and make the contacting surfaces equiplanar, with each carton in rm contact with the adjacent carton, the maximum 15 p.s.i. pressure bein-g below the pressure at which the corrugations are crushed.

5. A method for making a self-palletized bale of K.D.F. corrugated paper cartons, comprising the steps of: stacking K.D.F. cartons with a bottom oversize corrugated paper locking sheet at the bottom of the resultant stack and an upper oversize corrugated paper locking sheet over said stack; folding the portions of said locking sheets that extend beyond said stack against the opposite faces of the stack; placing overlength corrugated paper bumper strips at spaced intervals over the top of the upper locking sheet and beneath the bottom of the bottom locking sheet; folding the overlength end portions of said bumper strips against the stack and over the folded portions of said locking sheets; positioning rabbeted boards, rabbet outward, against one of said faces of the stack, each upon and between the folded end portions of an upper and a lower said bumper strip, with the ends of said rabbeted boards being in hold down relation with said bumper strips, passing metal straps around said stack, each said strap lying in the rabbet of a said board and overlying some of said bumper strip for substantially the full length of said bumper strips; securing the ends of said strap together tightly to form a bale; and

then turning said bale 90 to rest it on said boards, which are then used as pallet boards.

6. A method for packaging K.D.F. corrugated cartons into a self-palletized bale, comprising the steps of: stacking a first lgroup of K.D.F. cartons; stacking a second vgroup of K.D.F. cartons beside said first stack and parallel thereto; placing a single oversize lower locking sheet beneath the bottom of both said stacks; placing an upper locking sheet over the top of both said stacks; folding marginal portions of said upper locking sheet downwardly and like marginal portions of said lower locking sheet upwardly, against a marginal portion of those opposite faces common to both said stacks; placing a pair of bumper strips over the top of the upper locking sheet at symmetric locations with respect thereto; placing a pair of bumper strips similarly beneath the bottom of the bottom locking sheet and in vertical alignment with respective upper bumper strips; turning over end portions Y 10 of said bumper strips against said opposite faces of said stacks; placing the stacks under high pressure; positioning two rabbeted boards, rabbeted faces out, on one of said faces of said stacks, one along each stack, parallel to each other and between and against the turned over portions of said bumper strips; passing a pair of metal bands around said stacks, each said band passing along in the rabbets of said boards, overlying said upper bumper strips and the folded-back portions of all said bumper strips and underlying said lower bumper strips; securing the ends of said bands together to form a tightly held bale; and then turning said bale to rest on said boards, whereby said :boards form a pallet for said bale.

7. A method for packaging K.D.F. corrugated cartons, comprising the steps of: forming two stacks of identical height of K.D.F. cartons side-by-side over an oversize locking sheet; placing an upper locking sheet over the top of both said stacks, folding marginal portions of said upper locking sheet downwardly and like marginal portions of said lower locking sheet upwardly, against a marginalportion ofthe opposite faces shared by said two stacks; placing a pair of bumper strips over the top of the upper locking sheet at symmetric locations with respect thereto and generally centered with respect to each stack and having end -portions folded over said stack faces; placing a pair of like bumper strips beneath the bottom of the bottom locking sheet in alignment with respective upper bumper strips, with folded end portions in line with those of the upper strips; positioning two rabbeted runners, rabbeted face out, on one of said opposite faces of said stacks, parallel to each other and over said bumper strips; placing said stacks under pressure and retaining said stacks under pressure while passing a pair of metal straps along in the rabbets of said runners and over said upper bumper strips; securing said straps together to form a bale; and then turning said bale 90 to rest it on said runners.

8. A method for packaging KDF. corrugated cartons, comprising the steps of: stacking two groups of K.D.F. cartons side-by-side with their ends aligned and their upper and lower faces aligned; placing a single oversize corrugated paper lower sheet beneath sai'cl stacks; placing a similar upper sheet over said stacks; folding marginal portions of said upper sheet downwardly and like marginal portions of said lower sheet upwardly, against a marginal portion of the opposite faces common to both of said stacks; placing a pair of upper, corrugated paper, overlength strips over the top of the upper sheet at symmetric locations with respect thereto; placing a pair of similar lower strips beneath the bottom of the bottom sheet and in line below respective upper strips; folding portions of said strips over against said opposite stack faces; positioning two runners with longitudinal grooves, groove outward, on one of said faces of said stacks, parallel to each other and over the folded end portions of said strips; passing a pair of metal bands therearound, said bands lying in said grooves and overlying said strips; securing together the ends of said bands to form a palletized bale; and then turning said bale 90 to rest on said runners,

9. A method for forming a shipping and storing unit of K.D.F. corrugated cartons, comprising the steps of: stacking a firstgroup of K.D.F. cartons; stacking a second similar group of K.D.F. cartons beside said first stack; placing an oversize lower sheet beneath both said stacks; placing an upper sheet over both said stacks; folding marginal portions of said upper sheet downwardly and like marginal portions of said lower sheet upwardly, against a marginal portion of .the opposite faces common to both stacks; placing a pair of overlength bumper strips over the top of the upper sheet at symmetric locations with respect thereto; placing a pair of overlength bumper strips similarly beneath the bottom of the bottom sheet; folding the overlength ends against said faces of said stacks; positioning two rabbeted pallet boards, rabbeted face out, on one endedge of said stacks, one along each stack, parallel to each other and with their end portions resting on folded-over portions of said bumper strips; securing a pair of metal bands around said stacks, said bands passing along in the rabbets of said boards and overlying said :bumper strips and their foldedyback portions, forming a first, self-palletized bale; stacking a third group of K.D.F. cartons; stacking a fourth group of K.D.F. cartons; placing an upper overlength bumper strip centrally over each of said third and fourth groups; similarly placing an overlength lower bumper strip beneath each of said third and fourth groups; folding the ends of said strips against said groups; strapping said third and fourth groups, each by a single .band that overlies said bumper strips, to form second and third bales; placing said bales side-by-side and both against the end of said rst `bale opposite the pallet boards; and then turning said bales 90 to rest the complete unit on said boards.

10. A method for making a self-palletized package of K.D.F. corrugated cartons, comprising the steps of: stacking K.D.F. cartons horizontally in a plurality of stacks side by side with common top and bottom planes, two opposite common vertical planes, and upper and lower collinear corners where said vertical planes meet said top and bottom planes; uniting said stacks into a single group by placing flanged tension means along said collinear corners with portions bearing on said top and bottom planes and flanges bearing on said common vertical planes; exerting pressure on said groups of stacks suicient to make the cartons equiplanar and to squeeze out the air between them Without damage to the individual cartons; positioning runners vcrtically against one end of said group at one of said common vertical planes said runners bridging between flanges of opposite said anged tension means; passing metal bands around said single group while it is still under pressure, each said band lying along and against a said runner; securing the ends of said band together tightly; and then turning the resultant bale to rest it on said runners, which are then used as pallet rails.

References Cited in the le of this patent UNITED STATES PATENTS 1,785,360 Payzant Dec. 16, 1930 1,869,127 Allen et al. July 26, 1932 2,065,650 Burke Dec. 24, 1936 2,425,301 Browner Aug. 12, 1947 2,485,789 r[Thomas Oct. 25, 1949 2,626,456 Harrison Jan. 27, 1953 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent NoE 2,896,207 July 2l, Q59

Harry IIL Wilson It is herebr certified that error appears in the -printed specification of the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Column 2, line 66, for "cartons" read carton Column A, line 22, for Htable lO" read bale lO column 5, line '74, for "unsable" read musable column 6, line 42, for "K.F.D." read K.DF. ne; column 8, line 23, for "sipirt" read spirit line 29, for "any" read and "g line 65, for "top and bottom the stack" read top and bottom of the stack n; column 9, line 53, for "bumper strips," read bumper strips; en.,

Signed and sealed this 8th day of March 1960.,

(SEAL) Attest:

KARL H@ AXLINE ROBERT C. WATSON Attesting Officer Commissioner of Patents 

